CoolRaptor2001 Posted November 25, 2003 Report Posted November 25, 2003 My shifter has been slipping real bad because the teeth on the shift lever its self are gone, as well as the bolt that goes thru the lever. so I put a new bolt, same size and everything, thru the lever and slowly tightened it down. It went on easy, just like the original bolt. BUT, when I checked the shift lever by shaking it, it fell straight down. I took the lever back off to discover the shift shaft now has a half circle cut in it. Like I used a to large of bolt or something only I didnt. Needless to say, I need a new one. What all is involved in changing the shift shaft? does the motor have to come out and be taken all apart like iam thinking? Quote
ledofthezep Posted November 25, 2003 Report Posted November 25, 2003 Dunno for sure, haven't been there myself...but it sounds like you'll probably be cracking the cases,...if nothing else to clean up any broken chunks of grunt that may be in there. That sucks man,...hope you get it figured out. I'm sure there will be more helpful replies... Quote
Leadfoot350 Posted November 25, 2003 Report Posted November 25, 2003 if you dont have a cylmer manual then this is the time to buy one. Just take off the right side cover but drain the oil first. You will see how the shift shaft is put in there so now if you can do it with out the manual then just replace it. Dealer sells them for 30 buxs. Quote
CoolRaptor2001 Posted November 25, 2003 Author Report Posted November 25, 2003 Thats what I was worried about, cracking the cases. Would I have to do that if I just took the right side cover off? Once its ''un-hooked'' from the stuff on the right side will it just slide out or is there any other stuff i gotta watch out for? Thanks for your quick replies Quote
kenr74 Posted November 25, 2003 Report Posted November 25, 2003 If you want to do it quickly just stand her up on the left side so all the oil flows down into the case. Then take the right side cover off. Pull the old one and put the new one in. Ten minutes and you are done. Quote
CoolRaptor2001 Posted November 25, 2003 Author Report Posted November 25, 2003 Oh..that easy huh? THANKS alot, i was worried for a while there thinking I would have to split the cases and all that Thanks for your replies everyone, dunno what I would do without your help (even though ive only had my shee 3 days) Thanks again! Quote
rebelbanshee2 Posted November 25, 2003 Report Posted November 25, 2003 tipping it on its side will not be a good idea in this case. once the shaft is removed what is going to keep the oil in on the side that is now tipped towards the ground??? nothing!!! the oil needs to be drained and i think the clutch basket has to come off too Quote
Aussie Quad Racer Posted November 25, 2003 Report Posted November 25, 2003 1. there is supposed to be a half moon cut into your shift shaft. It is so the bolt will go through without fouling. 2. Is the spline worn off the shift shaft or the shifter? Make sure you know which is worn. 3. To remove the shift shaft(if nessacary) Drain oil, Remove clutch cover, Remove clutch and basket, remove shifter(if you havent done so already), pull the shift shaft right outa there. Quote
kenr74 Posted November 25, 2003 Report Posted November 25, 2003 once the shaft is removed what is going to keep the oil in on the side that is now tipped towards the ground??? nothing!!! The oil would go into the case. The shift shaft runs towards the back of the cases but I don't think it is where the oil can get to. I could be wrong on that but I don't remember any oil seals in the area the shaft goes through. You do have to take the clutch off though. Quote
CoolRaptor2001 Posted November 25, 2003 Author Report Posted November 25, 2003 The shaft AND shifter are badly worn. But iam pretty sure the half moon wasent in there earlier because ive had the shifter off like 5 times trying to figure out how to keep it from slipping. Ok so I guess ill drain the oil just to be safe. Is the clutch hard to remove? Iam gonna get a clymers manual when I go to the stealership and order a new shift shaft and I might as well pick one up then. WIll the manual show me how to do all that without damaging anything? I cant afford nor do I want to take it somewere to have it worked on but I dont want to mess it up anymore than I have too Quote
Blacksmith Posted November 25, 2003 Report Posted November 25, 2003 There should be a half moon cut in the shift shaft. If you put a new bolt in the shifter lever and it "turned strait down" then I doubt that it was all the way on the shaft. The bolt should have slotted into that cut and stopped the lever from going that far. Like was mentioned before, make sure you check to see if the splines are bad on the shifter lever or the shift shaft. If there is any doubt, remember that the shaft is steel, where as the lever is not. As for removing the shift shaft, remove the shifter lever and tip the bike on its left side. Remove a small amount of water from the Rad, about a quart or so. Pull the right side motor or "clutch" cover off. Pull off the clutch basket and lift the shift lever strait out the top. You will lose only a small amount of oil out the left side of that shift shaft passage. Drop in a new one, check the adjustment, and reinstall the clutch. Button everything back up, and put your water back in. You are done. Good Luck. Quote
kenr74 Posted November 25, 2003 Report Posted November 25, 2003 Ok, I must have been smoking crack or something. We did a little field repair once and now I remember what we did. We basically had the bike on it's side but also with the back end off the ground. That way we didn't have to drain the oil and we could pull the shifter off and adjust it. If you have it in the garage though just drain it, stand it up and go to work. You will have to take the brake and foot peg off too. Quote
CoolRaptor2001 Posted November 25, 2003 Author Report Posted November 25, 2003 I just went out in the garage and checked it. I bolted it back up and it was still slipping so I took it back off, cleaned out all the splines, then put it back on there with the shift lever angle down more than I had it earlier. The shift lever is still real loose but it refuses to skip or come off with the bolt in it now. See, the night I brought it home I adjusted the shift lever up some because I couldnt reach it very good. I guess that made it so it wouldnt sit in that 'half moon' thing and thats why it was slipping. I guess it was just me being stupid that I didnt notice that half moon on that shaft earlier since I had the shift lever off so many times Fun fun....sorry for taking up all your time on something SO stupid Quote
lincster Posted November 26, 2003 Report Posted November 26, 2003 My buddy just did his, you have to drain the oil, pull the clutch basket and then the shaft will slide out. While you have it out, replace the oil seal that is on the shifter side of the bike. It will start leaking eventually, mine did. Quote
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